Multilayer ceramic electronic component

ABSTRACT

A multilayer ceramic electronic component includes: a ceramic body including dielectric layers and a plurality of internal electrodes disposed to face each other with each of the dielectric layers interposed therebetween; and external electrodes disposed on external surfaces of the ceramic body and electrically connected to the internal electrodes, respectively, in which the external electrode each include an electrode layer electrically connected to the internal electrodes and a plating layer disposed on the electrode layer, and a thickness of the electrode layer in a cross section of the ceramic body in first and second directions is  10  μm or more.

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application claims the benefit of priority to Korean PatentApplication No. 10-2018-0104703 filed on Sep. 3, 2018 in the KoreanIntellectual Property Office, the disclosure of which is incorporatedherein by reference in its entirety.

TECHNICAL FIELD

The present disclosure relates to a multilayer ceramic electroniccomponent, and more particularly, to a method of manufacturing amultilayer ceramic electronic component having excellent reliability.

BACKGROUND

Generally, electronic components using a ceramic material, such as acapacitor, an inductor, a piezoelectric element, a varistor, athermistor, and the like, include a ceramic body formed of the ceramicmaterial, internal electrodes formed in the ceramic body, and externalelectrodes installed on surfaces of the ceramic body to be connected tothe internal electrodes.

A multilayer ceramic capacitor, among multilayer ceramic electroniccomponents, includes a plurality of stacked dielectric layers, internalelectrodes disposed to face each other with each of the dielectriclayers interposed therebetween, and external electrodes electricallyconnected to the internal electrodes.

The multilayer ceramic capacitor has been widely used as components ofmobile communications devices such as a computer, a personal digitalassistant (PDA), a cellular phone, and the like, since it has a smallsize, implements high capacitance, and may be easily mounted.

Recently, in accordance with performance improvement and thinness andlightness of electrical and electronic devices, a size decrease,performance improvement, and an increase in capacitance of electroniccomponents have been demanded.

Particularly, in accordance with an increase in capacitance andminiaturization of the multilayer ceramic capacitor, technology ofsignificantly increasing capacitance per unit volume has been required.

Therefore, the high capacitance needs to be implemented by significantlydecreasing a volume of the internal electrodes while implementing anarea of the internal electrodes as much as possible to increase thenumber of stacked layers.

However, in accordance with the capacitance increase and theminiaturization of the multilayer ceramic capacitor, it has beenimportant to secure reliability, particularly, moisture proofreliability, of the multilayer ceramic capacitor.

SUMMARY

An aspect of the present disclosure may provide a multilayer ceramicelectronic component having excellent reliability, and a method ofmanufacturing the same.

According to an aspect of the present disclosure, a multilayer ceramicelectronic component may include: a ceramic body including dielectriclayers and a plurality of internal electrodes disposed to face eachother with each of the dielectric layers interposed therebetween, andhaving first and second surfaces opposing each other in a firstdirection, third and fourth surfaces connected to the first and secondsurfaces and opposing each other in a second direction, and fifth andsixth surfaces connected to the first to fourth surfaces and opposingeach other in a third direction; and external electrodes disposed onexternal surfaces of the ceramic body and electrically connected to theinternal electrodes, respectively, wherein the external electrodeincludes an electrode layer electrically connected to the internalelectrodes and a plating layer disposed on the electrode layer, and athickness of the electrode layer in a cross section of the ceramic bodyin the first and second directions is 10 μm or more.

According to another aspect of the present disclosure, a multilayerceramic electronic component may include: a ceramic body includingdielectric layers and a plurality of internal electrodes disposed toface each other with each of the dielectric layers interposedtherebetween, and having first and second surfaces opposing each otherin a first direction, third and fourth surfaces connected to the firstand second surfaces and opposing each other in a second direction, andfifth and sixth surfaces connected to the first to fourth surfaces andopposing each other in a third direction; and external electrodesdisposed on external surfaces of the ceramic body and electricallyconnected to the internal electrodes, respectively, wherein the externalelectrode includes an electrode layer electrically connected to theinternal electrodes and a plating layer disposed on the electrode layer,and a thickness of the electrode layer in a cross section of the ceramicbody in the first and third directions is 7 μm or more.

BRIEF DESCRIPTION OF DRAWINGS

The above and other aspects, features, and advantages of the presentdisclosure will be more clearly understood from the following detaileddescription taken in conjunction with the accompanying drawings, inwhich:

FIG. 1 is a schematic perspective view illustrating a multilayer ceramiccapacitor according to an exemplary embodiment in the presentdisclosure;

FIG. 2 is a schematic view illustrating a ceramic body according to anexemplary embodiment in the present disclosure;

FIG. 3 is a cross-sectional view taken along line I-I′ of FIG. 1;

FIG. 4 is an enlarged view of region B of FIG. 3;

FIG. 5 is a cross-sectional view taken along line II-II′ of FIG. 1; and

FIG. 6 is an enlarged view of region C of FIG. 5.

DETAILED DESCRIPTION

Hereinafter, exemplary embodiments of the present disclosure will now bedescribed in detail with reference to the accompanying drawings.

An exemplary embodiment in the present disclosure relates to a ceramicelectronic component, and an example of an electronic component using aceramic material may include a capacitor, an inductor, a piezoelectricelement, a varistor, a thermistor, or the like. Hereinafter, amultilayer ceramic capacitor will be described as an example of theceramic electronic component.

FIG. 1 is a schematic perspective view illustrating a multilayer ceramiccapacitor according to an exemplary embodiment in the presentdisclosure.

FIG. 2 is a schematic view illustrating a ceramic body according to anexemplary embodiment in the present disclosure.

FIG. 3 is a cross-sectional view taken along line I-I′ of FIG. 1.

FIG. 4 is an enlarged view of region B of FIG. 3.

Referring to FIGS. 1 through 4, a multilayer ceramic capacitor accordingto an exemplary embodiment in the present disclosure may include aceramic body 110, internal electrodes 121 and 122 formed in the ceramicbody, and external electrodes 131 and 132 formed on external surfaces ofthe ceramic body 110.

In an exemplary embodiment in the present disclosure, a ‘lengthdirection’ of the multilayer ceramic capacitor refers to an ‘L’direction of FIG. 1, a ‘width direction’ of the multilayer ceramiccapacitor refers to a ‘W’ direction of FIG. 1, and a ‘thicknessdirection’ of the multilayer ceramic capacitor refers to a ‘T’ directionof FIG. 1. The ‘thickness direction’ refers to a direction in which thedielectric layers are stacked, that is, a ‘stack direction’.

A shape of the ceramic body 110 is not particularly limited, but may bea hexahedral shape according to an exemplary embodiment in the presentdisclosure.

The ceramic body 110 may have first and second surfaces S1 and S2opposing each other in a first direction, third and fourth surfaces S3and S4 connected to the first and second surfaces S1 and S2 and opposingeach other in a second direction, and fifth and sixth surfaces S5 and S6connected to the first to fourth surfaces and opposing each other in athird direction.

The first and second surfaces S1 and S2 refer to surfaces of the ceramicbody 110 opposing each other in the thickness direction, which is thefirst direction, the third and fourth surfaces S3 and S4 refer tosurfaces of the ceramic body 110 opposing each other in the lengthdirection, which is the second direction, and the fifth and sixthsurfaces S5 and S6 refer to surfaces of the ceramic body 110 opposingeach other in the width direction, which is the third direction.

One ends of a plurality of internal electrodes 121 and 122 formed in theceramic body 110 may be exposed to the third surface S3 or the fourthsurface S4 of the ceramic body 110.

The internal electrodes 121 and 122 may have a pair of first and secondinternal electrodes 121 and 122 having different polarities.

One ends of the first internal electrodes 121 may be exposed to thethird surface S3, and one ends of the second internal electrodes 122 maybe exposed to the fourth surface S4.

The other ends of the first internal electrodes 121 and the secondinternal electrodes 122 may be formed to be spaced apart from the fourthsurface S4 or the third surface S3 by a predetermined interval. Moredetailed contents for this will be described below.

First and second external electrodes 131 and 132 may be formed on thethird and fourth surfaces S3 and S4 of the ceramic body 110,respectively, and may be electrically connected to the internalelectrodes.

A thickness of each of the internal electrodes 121 and 122 is notparticularly limited, and may be, for example, 0.4 μm or less.

According to an exemplary embodiment in the present disclosure, thenumber of dielectric layers on which the internal electrodes are formedmay be 200 or more.

According to an exemplary embodiment in the present disclosure, theceramic body 110 may be formed by stacking a plurality of dielectriclayers 111.

The plurality of dielectric layers 111 forming the ceramic body 110 maybe in a sintered state, and adjacent dielectric layers may be integratedwith each other so that boundaries therebetween are not readilyapparent.

The dielectric layer 111 may be formed by sintering a ceramic greensheet including ceramic powders.

The ceramic powder is not particularly limited, and may be any ceramicpowder that is generally used in the related art.

The ceramic powder may include, for example, a BaTiO₃-based ceramicpowder, but is not limited thereto.

An example of the BaTiO₃-based ceramic powder may include(Ba_(1-x)Ca_(x))TiO₃, Ba(Ti_(1-y)Ca_(y))O₃,(Ba_(1-x)Ca_(x))(Ti_(1-y)Zr_(y))O₃, Ba(Ti_(1-y)Zr_(y))O₃, or the like,in which Ca, Zr, or the like, is partially solid-solved in BaTiO₃, butis not limited thereto.

In addition, the ceramic green sheet may include a transition metal,rare earth elements, magnesium (Mg), aluminum (Al), or the like,together with the ceramic powders.

A thickness of one dielectric layer 111 may be appropriately changed inaccordance with a capacitance design of the multilayer ceramiccapacitor.

A thickness of the dielectric layer 111 formed between two adjacentinternal electrode layers after being sintered may be, for example, 0.4μm or less, but is not limited thereto.

According to an exemplary embodiment in the present disclosure, thethickness of the dielectric layers 111 refers to an average thickness.

The average thickness of the dielectric layers 111 may be measured by animage, captured by a scanning electron microscope (SEM), of a crosssection of the ceramic body 110 in the length direction, as illustratedin FIG. 2.

For example, with respect to any dielectric layer extracted from animage, captured by the scanning electron microscope (SEM), of a crosssection of the ceramic body 110 cut in a length and thickness L-Tdirection at a central portion of the ceramic body 110 in the width Wdirection as illustrated in FIG. 2, thicknesses of the dielectric layermay be measured at thirty points arranged at equal intervals in thelength direction to measure an average value thereof.

The thirty points arranged at equal intervals may be measured in acapacitance forming portion that refers to a region in which theinternal electrodes 121 and 122 overlap each other.

In addition, when an average thickness of ten or more dielectric layersis measured, the average thickness of the dielectric layers may furtherbe generalized.

The ceramic body 110 may include an active portion A contributing toforming capacitance of the multilayer ceramic capacitor, and upper andlower cover portions C1 and C2 disposed on upper and lower surfaces ofthe active portion A, respectively, as upper and lower margin portions.

The active portion A may be formed by repeatedly stacking a plurality offirst and second internal electrodes 121 and 122 with each of thedielectric layers 111 interposed therebetween.

The upper and lower cover portions C1 and C2 may be formed of the samematerial as that of the dielectric layer 111 and have the sameconfiguration as that of the dielectric layer 111 except that they donot include the internal electrodes.

That is, the upper and lower cover portions C1 and C2 may include aceramic material such as a barium titanate (BaTiO₃)-based ceramicmaterial.

The upper and lower cover portions C1 and C2 may be formed by stacking asingle dielectric layer or two or more dielectric layers on the upperand lower surfaces of the active portion A, respectively, in a verticaldirection, and may basically serve to prevent damage to the internalelectrodes due to physical or chemical stress.

Each of the upper and lower cover portions C1 and C2 may have athickness of 20 μm or less, but is not necessarily limited thereto.

Recently, in accordance with performance improvement and thinness andlightness of electrical and electronic devices, a size decrease,performance improvement, and an increase in capacitance of electroniccomponents have been demanded. Therefore, the thicknesses of the upperand lower cover portions disposed in the ceramic body as described abovehave been decreased.

As in an exemplary embodiment in the present disclosure, when each ofthe upper and lower cover portions C1 and C2 has the thickness of 20 μmor less, the thickness of each of the upper and lower cover portions maybe small, such that external moisture and a plating solution may easilypermeate into the ceramic body. Therefore, it is likely that a moistureproof reliability defect of the multilayer layer capacitor will occur.

In order to solve such a problem, according to an exemplary embodimentin the present disclosure, the moisture proof reliability of themultilayer layer capacitor may be improved by controlling thicknesses ofelectrode layers in a cross section of the ceramic body in alength-thickness direction and a cross section of the ceramic body in awidth-thickness direction.

That is, in an exemplary embodiment in the present disclosure, asubminiature and high-capacitance multilayer ceramic capacitor, wheneach of the upper and lower cover portions C1 and C2 has the smallthickness of 20 μm or less, a thickness of an electrode layer includedin the external electrode may be controlled in order to improve themoisture proof reliability.

Therefore, in a multilayer ceramic capacitor according to the relatedart in which a thickness of each of the upper and lower cover portionsC1 and C2 exceeds 20 μm, even though the thicknesses of the electrodelayers in the cross section of the ceramic body in the length-thicknessdirection and the cross section of the ceramic body in thewidth-thickness direction are not controlled unlike an exemplaryembodiment in the present disclosure, the moisture proof reliability isnot problematic.

A material of each of the first and second internal electrodes 121 and122 is not particularly limited, but may be a conductive paste includingone or more of silver (Ag), lead (Pb), platinum (Pt), nickel (Ni), andcopper (Cu).

The multilayer ceramic capacitor according to an exemplary embodiment inthe present disclosure may include the first external electrode 131electrically connected to the first internal electrodes 121 and thesecond external electrode 132 electrically connected to the secondinternal electrodes 122.

The first and second external electrodes 131 and 132 may be electricallyconnected to the first and second internal electrodes 121 and 122,respectively, in order to form capacitance, and the second externalelectrode 132 may be connected to a potential different to a potentialto which the first external electrode 131 is connected.

The first and second external electrodes 131 and 132 may be disposed,respectively, on the third and fourth surfaces S3 and S4 of the ceramicbody 110 in the length direction, which is the second direction, and mayextend to the first and second surfaces S1 and S2 of the ceramic body110 in the thickness direction, which is the first direction.

The external electrodes 131 and 132 may include, respectively, electrodelayers 131 a and 132 a disposed on the external surfaces of the ceramicbody 110 and electrically connected to the internal electrodes 121 and122, respectively, and plating layers 131 b and 131 c, and 132 b and 132c disposed on the electrode layers 131 a and 132 a, respectively.

The external electrodes 131 and 132 may include the first externalelectrode 131 and the second external electrode 132 disposed on onesurface and the other surface of the ceramic body 110, respectively.

The electrode layers 131 a and 132 a may include a conductive metal anda glass.

The conductive metal used in the electrode layers 131 a and 132 a may beany material that may be electrically connected to the internalelectrodes in order to form the capacitance, for example, one or moreselected from the group consisting of copper (Cu), silver (Ag), nickel(Ni), and alloys thereof.

The electrode layers 131 a and 132 a may be formed by applying and thensintering a conductive paste prepared by adding glass frit to conductivemetal powders.

That is, each of the electrode layers 131 a and 132 a may be a sinteringtype electrode formed by sintering the paste including the conductivemetal.

The conductive metal included in the electrode layers 131 a and 132 amay be electrically conducted to the first and second internalelectrodes 121 and 122 to implement electrical characteristics.

The glass included in the electrode layers 131 a and 132 a may serve asa sealing material blocking external moisture together with theconductive metal.

The first external electrode 131 may include a first electrode layer 131a disposed on one surface of the ceramic body 110 in the lengthdirection L, which is the second direction, and electrically connectedto the first internal electrodes 121, and first plating layers 131 b and131 c disposed on the first electrode layer 131 a.

In addition, the second external electrode 132 may include a secondelectrode layer 132 a disposed on the other surface of the ceramic body110 in the length direction L, which is the second direction, andelectrically connected to the second internal electrodes 122, and secondplating layers 132 b and 132 c disposed on the second electrode layer132 a.

The electrode layers 131 a and 132 a may be disposed on opposite endsurfaces of the ceramic body 110 in the length direction, respectively,and extend to portions of the first and second surfaces S1 and S2, whichare upper and lower surfaces of the ceramic body 110.

In addition, the plating layers 131 b and 131 c, and 132 b and 132 c maybe disposed on the electrode layers 131 a and 132 a, respectively.

The electrode layers 131 a and 132 a may be formed of the sameconductive metal as that of the first and second internal electrodes 121and 122, but are not limited thereto.

For example, the electrode layers 131 a and 132 a may be formed ofcopper (Cu), silver (Ag), nickel (Ni), or alloys thereof.

The plating layers 131 b, 131 c, 132 b, and 132 c may include nickelplating layers 131 b and 132 b and tin plating layers 131 c and 132 ceach disposed on the nickel plating layers 131 b and 132 b, but arelimited thereto.

According to an exemplary embodiment in the present disclosure, athickness T_(L) of each of the electrode layers 131 a and 132 a in across section of the ceramic body 110 in the first and second directionsmay be 10 μm or more.

The first direction of the ceramic body 110 refers to the thicknessdirection of the ceramic body 110, the second direction of the ceramicbody 110 refers to the length direction of the ceramic body 110, and thecross section of the ceramic body 110 in the first and second directionsrefers to a cross section of the ceramic body 110 in thelength-thickness direction.

The thickness T_(L) of each of the electrode layers 131 a and 132 a inthe cross section of the ceramic body 110 in the first and seconddirections may be controlled to be 10 μm or more to improve the moistureproof reliability of the multilayer ceramic electronic component.

That is, in order to prevent a decrease in the moisture proofreliability of the multilayer ceramic electronic component, thethickness TL of each of the electrode layers 131 a and 132 a in thecross section of the ceramic body 110 in the first and second directionsneeds to be at least 10 μm or more.

Particularly, in a product in which the dielectric layer and theinternal electrodes formed of thin films are used, such as a product inwhich a thickness of the dielectric layer 111 after being sintered is0.4 μm or less and a thickness of each of the first and second internalelectrodes 121 and 122 after being sintered is 0.4 μm or less, adecrease in the moisture proof reliability may be problematic.

Therefore, when the thickness of the dielectric layer 111 is 0.4 μm orless and the thickness of each of the first and second internalelectrodes 121 and 122 is 0.4 μm or less, the thickness T_(L) of each ofthe electrode layers 131 a and 132 a in the cross section of the ceramicbody 110 in the first and second directions needs to be controlled to be10 μm or more as in an exemplary embodiment in the present disclosure,in order to prevent the decrease in the moisture proof reliability.

When the thickness T_(L) of each of the electrode layers 131 a and 132 ain the cross section of the ceramic body 110 in the first and seconddirections is less than 10 μm, the moisture proof reliability of themultilayer ceramic electronic component may be decreased.

Particularly, in a case in which the thickness of the dielectric layer111 is 0.4 μm or less and the thickness of each of the first and secondinternal electrodes 121 and 122 is 0.4 μm or less, when the thicknessT_(L) of each of the electrode layers 131 a and 132 a in the crosssection of the ceramic body 110 in the first and second directions isless than 10 μm, the moisture proof reliability of the multilayerceramic electronic component may be decreased.

However, the thin films do not mean that the thicknesses of thedielectric layer 111 and the first and second internal electrodes 121and 122 are 0.4 μm or less, but may conceptually include that thethicknesses of the dielectric layer and the internal electrodes aresmaller than those of the multilayer ceramic capacitor according to therelated art.

Meanwhile, as the thickness T_(L) of each of the electrode layers 131 aand 132 a in the cross section of the ceramic body 110 in the first andsecond directions is increased from a value of 10 μm or more, themoisture proof reliability of the multilayer ceramic electroniccomponent may be improved, but there may be a limitation value in thethickness of each of the electrode layers 131 a and 132 a forimplementing a subminiature and high-capacitance multilayer ceramicelectronic component. Therefore, a separate upper limit value of thethickness of each of the electrode layers 131 a and 132 a is not limitedherein.

FIG. 5 is a cross-sectional view taken along line II-II′ of FIG. 1.

FIG. 6 is an enlarged view of region C of FIG. 5.

Referring to FIGS. 5 and 6, in the multilayer ceramic electroniccomponent 100 according to an exemplary embodiment in the presentdisclosure, in addition to the feature described above, a thickness Twof each of the electrode layers 131 a and 132 a in a cross section ofthe ceramic body 110 in the first and third directions may be 7 μm ormore.

The first direction of the ceramic body 110 refers to the thicknessdirection of the ceramic body 110, the third direction of the ceramicbody 110 refers to the width direction of the ceramic body 110, and thecross section of the ceramic body 110 in the first and third directionsrefers to a cross section of the ceramic body 110 in the width-thicknessdirection.

The thickness T_(W) of each of the electrode layers 131 a and 132 a inthe cross section of the ceramic body 110 in the first and thirddirections may be controlled to be 7 μm or more to improve the moistureproof reliability of the multilayer ceramic electronic component.

That is, in order to prevent a decrease in the moisture proofreliability of the multilayer ceramic electronic component, thethickness T_(W) of each of the electrode layers 131 a and 132 a in thecross section of the ceramic body 110 in the first and third directionsneeds to be at least 7 μm or more.

Particularly, in the product in which the dielectric layer and theinternal electrodes formed of the thin films are used, such as theproduct in which a thickness of the dielectric layer 111 after beingsintered is 0.4 μm or less and a thickness of each of the first andsecond internal electrodes 121 and 122 after being sintered is 0.4 μm orless, a decrease in the moisture proof reliability may be problematic.

Therefore, when the thickness of the dielectric layer 111 is 0.4 μm orless and the thickness of each of the first and second internalelectrodes 121 and 122 is 0.4 μm or less, the thickness Tw of each ofthe electrode layers 131 a and 132 a in the cross section of the ceramicbody 110 in the first and third directions needs to be controlled to be7 μm or more as in an exemplary embodiment in the present disclosure, inorder to prevent the decrease in the moisture proof reliability.

When the thickness T_(W) of each of the electrode layers 131 a and 132 ain the cross section of the ceramic body 110 in the first and thirddirections is less than 7 μm, the moisture proof reliability of themultilayer ceramic electronic component may be decreased.

Particularly, in a case in which the thickness of the dielectric layer111 is 0.4 μm or less and the thickness of each of the first and secondinternal electrodes 121 and 122 is 0.4 μm or less, when the thickness Twof each of the electrode layers 131 a and 132 a in the cross section ofthe ceramic body 110 in the first and third directions is less than 7μm, the moisture proof reliability of the multilayer ceramic electroniccomponent may be decreased.

Meanwhile, as the thickness Tw of each of the electrode layers 131 a and132 a in the cross section of the ceramic body 110 in the first andthird directions is increased from a value of 7 μm or more, the moistureproof reliability of the multilayer ceramic electronic component may beimproved, but there may be a limitation value in the thickness of eachof the electrode layers 131 a and 132 a for implementing a subminiatureand high-capacitance multilayer ceramic electronic component. Therefore,a separate upper limit value of the thickness of each of the electrodelayers 131 a and 132 a is not limited herein.

According to an exemplary embodiment in the present disclosure, in theproduct in which the dielectric layer and the internal electrodes formedof the thin films are used, such as the product in which the thicknessof the dielectric layer 111 after being sintered is 0.4 μm or less andthe thickness of each of the first and second internal electrodes 121and 122 after being sintered is 0.4 μm or less, the thickness T_(L) ofeach of the electrode layers 131 a and 132 a in the cross section of theceramic body 110 in the first and second directions may be 10 μm or moreand the thickness

Tw of each of the electrode layers 131 a and 132 a in the cross sectionof the ceramic body 110 in the first and third directions may be 7 μm ormore, in order to improve the moisture proof reliability.

That is, when the thickness T_(L) of each of the electrode layers 131 aand 132 a in the cross section of the ceramic body 110 in the first andsecond directions is 10 μm or more and the thickness T_(W) of each ofthe electrode layers 131 a and 132 a in the cross section of the ceramicbody 110 in the first and third directions is 7 μm or more, a moisturepermeability rate may be decreased, such that the moisture proofreliability may be improved.

When any one of the thickness T_(L) of each of the electrode layers 131a and 132 a in the cross section of the ceramic body 110 in the firstand second directions and the thickness Tw of each of the electrodelayers 131 a and 132 a in the cross section of the ceramic body 110 inthe first and third directions is out of a numeral range of the presentdisclosure, the moisture proof reliability may be decreased.

A method of manufacturing a multilayer ceramic capacitor according to anexemplary embodiment in the present disclosure will hereinafter bedescribed.

According to an exemplary embodiment in the present disclosure, aplurality of ceramic green sheets may be prepared.

The ceramic green sheet may be manufactured by mixing ceramic powders, abinder, a solvent, and the like, with one another to prepare slurry andmanufacturing the slurry in a sheet shape having a thickness of severalmicrometers by a doctor blade method. Then, the ceramic green sheet maybe sintered to form one dielectric layer 111 as illustrated in FIG. 2.

A thickness of the ceramic green sheet may be 0.6 μm or less. Therefore,a thickness of the dielectric layer after being sintered may be 0.4 μmor less.

Then, a conductive paste for an internal electrode may be applied to theceramic green sheets to form internal electrode patterns. The internalelectrode patterns may be formed by a screen printing method or agravure printing method.

The conductive paste for an internal electrode may include a conductivemetal and an additive. The additive may be one or more of a non-metal ora metal oxide.

The conductive metal may include nickel. The additive may include bariumtitanate or strontium titanate as the metal oxide.

A thickness of the internal electrode pattern may be 0.5 μm or less.Therefore, a thickness of the internal electrode after being sinteredmay be 0.4 μm or less.

Then, the ceramic green sheets on which the internal electrode patternsare formed may be stacked and pressed in the stack direction. Therefore,a ceramic laminate in which the internal electrode patterns are formedmay be manufactured.

Then, the ceramic laminate may be cut per region corresponding to onecapacitor to be manufactured in a chip form.

In this case, the ceramic laminate may be cut so that one ends of theinternal electrode patterns are alternately exposed through endsurfaces.

Then, the laminate manufactured in the chip form may be sintered tomanufacture the ceramic body.

The sintering process may be performed in a reducing atmosphere. Inaddition, the sintering process may be performed while controlling atemperature raising speed.

The temperature raising speed may be 30° C./60 s to 50° C./60 s at 700°C. or less.

Then, the external electrodes covering the end surfaces of the ceramicbody and electrically connected to the internal electrodes exposed tothe end surfaces of the ceramic body may be formed. Then, plating layersformed of nickel, tin, or the like, may be formed on surfaces of theexternal electrodes.

Hereinafter, the present disclosure will be described in detail withreference to Inventive Example and Comparative Example.

Multilayer ceramic capacitors according to Inventive Examples andmultilayer ceramic capacitors according to Comparative Examples wereprepared by the following method.

Barium titanate powders, ethanol as an organic solvent, and polyvinylbutyral as a binder were mixed with one another and were ball-milled toprepare slurry. Then, a ceramic green sheet was manufactured using theslurry.

A conductive paste for an internal electrode containing nickel wasprinted on the ceramic green sheets to form the internal electrodes, anda green laminate formed by stacking the ceramic green sheets wasisostatically pressed at 85° C. and at a pressure of 1,000 kgf/cm².

The pressed green laminate was cut to manufacture a green chip, ade-binder process in which the cut green ship is maintained at 230° C.under an atmospheric condition for 60 hours was performed, and the greenchip was sintered at 1000° C. to manufacture a sintered chip. Thesintering was performed in a reducing atmosphere to prevent oxidation ofthe internal electrodes, and the reducing atmosphere was 10⁻¹¹ to 10⁻¹⁰atm lower than Ni/NiO equilibrium oxygen partial pressure.

Electrode layers were formed on external surfaces of the sintered chipusing a paste for an external electrode including copper powders andglass powders, and nickel plating layers and tin plating layers wereformed on the electrode layers by electroplating.

A multilayer ceramic capacitor having a 0603 size was manufactured bythe abovementioned method. The 0603 size may have a length and a widthof 0.6 μm±0.1 μm and 0.3 μm±0.1 μm, respectively. Features of themultilayer ceramic capacitor were evaluated as follows.

Table 1 illustrates measurement results of moisture permeability ratesdepending on thicknesses T_(L) and T_(W) of electrode layers includingthe copper powders and the glass powders according to ComparativeExamples and Inventive Examples.

Measurement of the moisture permeability rates was performed at eachthickness on four hundred samples with respect to each of ComparativeExamples and Inventive Examples.

TABLE 1 Thickness TL (μm) of Thickness TW (μm) of Number of ElectrodeLayer in Electrode Layer in Reliability Length Direction Width DirectionDefects 1* 5 4 15/400  2* 5 7 12/400  3* 5 10 13/400  4* 8 4 4/400 5* 87 1/400 6* 8 10 1/400 7* 10 4 2/400 8  10 7 0/400 9  10 10 0/400 10*  154 1/400 11  15 7 0/400 12  15 10 0/400 13*  20 4 1/400 14  20 7 0/40015  20 10 0/400 *Comparative Example

It may be seen from Table 1 that in Samples 1 to 6, which areComparative Examples in which the thicknesses T_(L) of each of theelectrode layers 131 a and 132 a in the cross section of the ceramicbody 110 in the first and second directions are less than 10 μm, amoisture proof reliability defect occurs regardless of the thicknessesTw of each of the electrode layers 131 a and 132 a in the cross sectionof the ceramic body 110 in the first and third directions.

In addition, it may be seen that in Sample 7, which is a ComparativeExample in which the thickness T_(L) of each of the electrode layers 131a and 132 a in the cross section of the ceramic body 110 in the firstand second directions is 10 μm, but the thickness T_(W) of each of theelectrode layers 131 a and 132 a in the cross section of the ceramicbody 110 in the first and third directions is less than 7 μm, there is aproblem in the moisture proof reliability.

On the other hand, it may be seen that in Samples 8, 9, 11, 12, 14, and15, which are Inventive Examples in which the thicknesses T_(L) of eachof the electrode layers 131 a and 132 a in the cross section of theceramic body 110 in the first and second directions and the thicknessesTw of each of the electrode layers 131 a and 132 a in the cross sectionof the ceramic body 110 in the first and third directions are in anumerical range of the present disclosure, a high-capacitance multilayerceramic capacitor having excellent moisture proof reliability may beimplemented.

Meanwhile, it may be seen that in Samples 10 and 13, which areComparative Examples in which the thicknesses T_(L) of each of theelectrode layers 131 a and 132 a in the cross section of the ceramicbody 110 in the first and second directions are 15 μm and 20 μm, whichare 10 μm or more, but the thicknesses Tw of each of the electrodelayers 131 a and 132 a in the cross section of the ceramic body 110 inthe first and third directions are less than 7 μm, there is a problem inthe moisture proof reliability.

As set forth above, according to an exemplary embodiment in the presentdisclosure, a thickness of a sintered electrode layer including theconductive metal and the glass in the external electrode may becontrolled to improve moisture proof characteristics, resulting inimprovement of reliability of the multilayer ceramic electroniccomponent.

While exemplary embodiments have been shown and described above, it willbe apparent to those skilled in the art that modifications andvariations could be made without departing from the scope of the presentinvention as defined by the appended claims.

1. A multilayer ceramic electronic component comprising: a ceramic bodyincluding dielectric layers and a plurality of internal electrodesdisposed to face each other with each of the dielectric layersinterposed therebetween, and having first and second surfaces opposingeach other in a first direction, third and fourth surfaces opposing eachother in a second direction and connected to the first and secondsurfaces, and fifth and sixth surfaces opposing each other in a thirddirection and connected to the first to fourth surfaces; and externalelectrodes disposed on the third and fourth surfaces of the ceramic bodyin the second direction and electrically connected to the plurality ofinternal electrodes, respectively, wherein the ceramic body includes anactive portion in which capacitance is formed by including the pluralityof internal electrodes and cover portions disposed on upper and lowersurfaces of the active portion, respectively, wherein a distance fromthe first surface of the ceramic body to an uppermost layer of theplurality of internal electrodes, or a distance from the second surfaceof the ceramic body to a lowermost layer of the plurality of internalelectrodes, is 20 μm or less, wherein the external electrodes eachinclude an electrode layer electrically connected to the plurality ofinternal electrodes and a plating layer disposed on each electrode layerof the external electrodes, wherein a thickness of each electrode layerof the external electrodes, which is an innermost layer of each of theexternal electrodes, in a cross section of the ceramic body in the firstand second directions is 10 μm or more and less than 100 μm wherein athickness of each electrode layer of the external electrodes in a crosssection of the ceramic body in the first and third directions is 7 μm ormore, and wherein a thickness of each of the dielectric layers is 0.4 μmor less, and a thickness of each of the plurality of internal electrodesis 0.4 μm or less.
 2. (canceled)
 3. (canceled)
 4. (canceled)
 5. Themultilayer ceramic electronic component of claim 1, wherein eachelectrode layer of the external electrodes is made of the sameconductive metal as a material of the plurality of internal electrodes.6. The multilayer ceramic electronic component of claim 1, wherein theplating layer includes a nickel plating layer and a tin plating layerdisposed on the nickel plating layer.
 7. A multilayer ceramic electroniccomponent comprising: a ceramic body including dielectric layers and aplurality of internal electrodes disposed to face each other with eachof the dielectric layers interposed therebetween, and having first andsecond surfaces opposing each other in a first direction, third andfourth surfaces opposing each other in a second direction and connectedto the first and second surfaces, and fifth and sixth surfaces opposingeach other in a third direction and connected to the first to fourthsurfaces; and external electrodes disposed on the third and fourthsurfaces of the ceramic body in the second direction and electricallyconnected to the plurality of internal electrodes, respectively, whereinthe ceramic body includes an active portion in which capacitance isformed by including the plurality of internal electrodes and coverportions disposed on upper and lower surfaces of the active portion,respectively, wherein a distance from the first surface of the ceramicbody to an uppermost layer of the plurality of internal electrodes, or adistance from the second surface of the ceramic body to a lowermostlayer of the plurality of internal electrodes, is 20 μm or less, whereinthe external electrodes each include an electrode layer electricallyconnected to the plurality of internal electrodes and a plating layerdisposed on each electrode layer of the external electrodes, wherein athickness of each electrode layer of the external electrodes, which isan innermost layer of each of the external electrodes, in a crosssection of the ceramic body in the first and third directions is 7 μm ormore and less than 100 μm, wherein a thickness of each electrode layerof the external electrodes in a cross section of the ceramic body in thefirst and second directions is 10 μm or more and less than 100 μm, andwherein a thickness of each of the dielectric layers is 0.4 μm or less,and a thickness of each of the plurality of internal electrodes is 0.4μm or less.
 8. (canceled)
 9. (canceled)
 10. The multilayer ceramicelectronic component of claim 7, wherein each electrode layer of theexternal electrodes is made of the same conductive metal as a materialof the plurality of internal electrodes.
 11. The multilayer ceramicelectronic component of claim 7, wherein the plating layer includes anickel plating layer and a tin plating layer disposed on the nickelplating layer.
 12. A multilayer ceramic electronic component comprising:a ceramic body including dielectric layers and having first and secondsurfaces opposing each other in a thickness direction, third and fourthsurfaces opposing each other in a length direction and connected to thefirst and second surfaces, and fifth and sixth surfaces opposing eachother in a width direction and connected to the first to fourthsurfaces; a plurality of internal electrodes disposed in the ceramicbody, each having one end exposed to the third or fourth surface in thelength direction; and external electrodes disposed on the third andfourth surfaces of the ceramic body and extending in the lengthdirection to cover portions of the first, second, fifth, and sixthsurfaces of the ceramic body, wherein the ceramic body includes anactive portion in which capacitance is formed by including the pluralityof internal electrodes and cover portions disposed on upper and lowersurfaces of the active portion, respectively, wherein a distance fromthe first surface of the ceramic body to an uppermost layer of theplurality of internal electrodes, or a distance from the second surfaceof the ceramic body to a lowermost layer of the plurality of internalelectrodes, is 20 μm or less, wherein the external electrodes eachinclude an electrode layer electrically connected to the plurality ofinternal electrodes and a plating layer disposed on each electrode layerof the external electrodes, and wherein a thickness of each electrodelayer of the external electrodes, which is an innermost layer of each ofthe external electrodes, in the length direction of the ceramic body is10 μm or more and less than 100 μm, wherein a thickness of eachelectrode layer of the external electrodes in the width direction is 7μm or more, and wherein a thickness of each of the dielectric layers is0.4 μm or less, and a thickness of each of the plurality of internalelectrodes is 0.4 μm or less.
 13. (canceled)
 14. (canceled) 15.(canceled)
 16. The multilayer ceramic electronic component of claim 12,wherein each electrode layer of the external electrodes is made of thesame conductive metal as a material of the plurality of internalelectrodes.
 17. The multilayer ceramic electronic component of claim 12,wherein the plating layer includes a nickel plating layer and a tinplating layer disposed on the nickel plating layer.